Automated pusher mechanisms for packaging systems

ABSTRACT

Automated pusher mechanisms with pusher heads that reciprocally travel in a product chute. The pusher head has an inverted “V” shape and semi-circular side portions.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/134,546, filed Jun. 6, 2008, which issued as U.S. Pat. No. 7,832,182on Nov. 16, 2010, which is a continuation of U.S. application Ser. No.11/674,404, filed Feb. 13, 2007, which issued as U.S. Pat. No. 7,386,966on Jun. 17, 2008, which is a continuation of U.S. application Ser. No.10/951,578, filed Sep. 28, 2004, which issued as U.S. Pat. No. 7,313,896on Jan. 1, 2008, which claims priority to U.S. Provisional ApplicationSer. No. 60/508,609, filed Oct. 3, 2003, the contents of which arehereby incorporated by reference as if recited in full herein.

FIELD OF THE INVENTION

The present invention relates to apparatus that can package and applyclosure clips to materials that enclose products therein, and may beparticularly suitable for clipping netting material.

BACKGROUND OF THE INVENTION

Certain types of commodity and/or industrial items can be packaged byplacing the desired product(s) in a covering material and then applyinga closure clip or clips to end portions of the covering material tosecure the product(s) therein. For non-flowable piece goods, the piecegoods can be held individually in a respective clipped package, or as agroup of goods in a single package. The covering material can be anysuitable material, typically a casing and/or netting material.

Generally described, when packaging a piece good product in netting, theproduct is manually pushed through a netting chute. The product caninclude, by way of example, a non-flowable semi-solid and/or solidobject such as a meat product including whole or half hams, turkey,chicken, and the like. The netting chute holds a length of a nettingsleeve over the exterior thereof. A first downstream end portion of thenetting is typically closed using a first clip. As the product exits thenetting chute, it is covered with the netting. An operator can thenorient the product inside the netting between the discharge end of thechute and the clipped first end portion of the netting. The operator canthen pull the netting so that the netting is held relatively tight(typically stretched or in tension) over the product. The operator thenuses his/her hands to compress or gather the open end of the netting(upstream of the product) and then manually applies a clip to thenetting, typically using a Tipper Tie® double clipper apparatus. A clipattachment apparatus or “clippers” are well known to those of skill inthe art and include those available from Tipper Tie, Inc., of Apex,N.C., including product numbers Z3214, Z3202, and Z3200. Examples ofclip attachment apparatus and/or packaging apparatus are descried inU.S. Pat. Nos. 3,389,533; 3,499,259; 4,683,700; and 5,161,347, thecontents of which are hereby incorporated by reference as if recited infull herein.

The double clipper concurrently applies two clips to the nettingproximate the open (upstream) end of the package. One clip defines thefirst end portion of the next package and the other defines the trailingor second end portion of the package then being closed. A cuttingmechanism incorporated in the clipper apparatus can sever the twopackages before the enclosed package is removed from the clipperapparatus. U.S. Pat. No. 4,766,713 describes a double clipper apparatusused to apply two clips to a casing covering. U.S. Pat. No. 5,495,701proposes a clipper with a clip attachment mechanism configured toselectively fasten a single clip or two clips simultaneously. Themechanism has two punches, one of which is driven directly by apneumatic cylinder and the other of which is connected to the firstpunch using a pin and key assembly. The pin and key assembly allows thepunches to be coupled or decoupled to the pneumatic cylinder drive toapply one single clip or two clips simultaneously. U.S. Pat. No.5,586,424 proposes an apparatus for movement of U-shaped clips along arail. The apparatus includes a clip feed for advancing clips on a guiderail and the arm is reciprocally driven by a piston and cylinderarrangement. The contents of each of these patents are herebyincorporated by reference as if recited in full herein.

SUMMARY OF EMBODIMENTS OF THE INVENTION

Embodiments of the present invention provide apparatus, subassembliesand/or other devices, systems, methods and computer program products forautomatically packaging a product in a covering material and/or applyingclips thereto.

In certain embodiments, the product can be manipulated and packaged sothat at least one clip is automatically applied to enclose the productin the covering material. Particular embodiments automatically package adiscrete object or objects in netting.

Certain embodiments are directed toward systems for automaticallyenclosing a semi-solid or solid product in a covering material. Thesystems include: (a) an elongate product chute having an outer surfaceand opposing receiving and discharge end portions with an interiorcavity extending therethrough; (b) a product pusher mechanism having apusher head that is configured to controllably automatically advanceinto and retract from the product chute to thereby advance a productfrom a position upstream of the product chute and through the productchute so as to exit out of the discharge end portion of the productchute; and (c) a clipper mechanism disposed downstream of the productchute, the clipper mechanism configured to automatically apply at leastone clip to a covering material that encloses the product from theproduct chute.

Other embodiments are directed toward methods of automatically packagingan object in a covering material such as casing and/or netting. Themethods include: (a) automatically pushing at least one object through aproduct chute; (b) pulling a covering material upstream of the productchute off an exterior surface of the product chute to automaticallyenclose the object in the covering material as the object exits theproduct chute; and then (c) applying a clip to the covering material tosecure the object in the packing material.

The pushing can include automatically extending a pusher head into theproduct chute to contact the object and force the object through theproduct chute and then retracting the pusher head from the productchute. The applying a clip may include automatically gathering thecovering material together and applying at least one clip to thegathered covering material. In particular embodiments, the applying stepcan include applying two proximately positioned but spaced apart clipssubstantially concurrently to the gathered covering material.

Other embodiments area directed to pivotable dual clipper assemblies forattaching closure clips to a product held in netting. The clipperassemblies include: (a) a retractable clipper mechanism having a clipperbody configured to deliver clips to a clip window and attach the clipsto netting; and (b) a pair of clipper gathering plates attached to theclipper body so that the clipper gathering plates retract with theclipper mechanism. In operation, the clipper gathering plates gathernetting upstream of a product held therein prior to attachment of clipsto the gathered netting by the clipper mechanism.

Still other embodiments are directed to automatic pivotable clippermechanisms for attaching closure clips to product held in a coveringmaterial. The mechanisms include: (a) a clipper body; (b) a curvilinearclip rail attached to the clipper body having opposing top and bottomend portions and defining a generally downwardly extending clip feeddirection; (c) a clip entry window in communication with the bottom endportion of the clip rail and a clip closure delivery path incommunication with a punch mechanism that is adapted to wrap a clip fromthe clip rail about a covering material; (d) a first clip pusherconfigured to selectively engage with clips held on the clip rail toforce the clips in the feed direction; (e) a first clipper gatheringplate attached to the clipper body on a first side of the clip entrywindow, the first clipper gathering plate configured to extend adistance below the clip rail and generally outwardly therefrom towardthe covering material; and (f) a second clipper gathering plate attachedto the clipper body on an opposing side of the clip entry window fromthat of the first clipper gathering plate so as to be spaced apart fromthe first clipper gathering plate. The second clipper gathering platecan be configured to extend a distance below the clip rail and generallyoutwardly therefrom toward the covering material. In operation, theclipper mechanism pivots from a rest position to an active clippingposition and the first and second clipper gathering plates pivot inconcert with the clipper mechanism.

Additional embodiments are directed toward brake assemblies for applyingpressure to a covering material that is automatically fed over aproduct. The devices include a pair of spaced apart arms, each havingrespective gripping members. The aims are configured to move toward eachother a distance sufficient to cause the gripping members to contact anouter surface of an intermediately positioned product chute with aninterior cavity and to move away from each other a distance sufficientto cause the gripping members to avoid contact with the outer surface ofthe product chute. The braking assemblies thereby controllablyselectively apply a braking force onto covering material held betweenthe outer surface of the product chute and the gripping members.

In particular embodiments, the gripping members have a curvilinearprofile when viewed from the side. The arms can be each pivotablyattached to a common center frame member. The brake assembly can alsoinclude an actuation cylinder that is attached to each arm and extendsbetween the arms so that the arms are configured to automaticallycontrollably pivot in concert toward and away from each other. The brakeassembly may be configured for braking netting. The device may, hence,further include a netting support roller positioned upstream of the armsso as to contact the underside of the product chute to tension thenetting as the netting exits the product chute.

In particular embodiments, the brake assembly is used in combinationwith a product chute with netting held on the outer surface of theproduct chute. The product chute can have sidewalls that aresubstantially curved and the gripping members can have a side profilewith a curved contour that substantially corresponds to that of theproduct chute sidewalls.

Yet other embodiments are directed toward methods of braking nettingtraveling over the outer surface of a product chute. The methodsinclude: (a) selectively moving first and second arms with grippingmembers thereon toward and away from a product chute; and (b) applying abraking force to netting traveling over an exterior surface of theproduct chute when the arms move a sufficient distance toward theproduct chute to press the netting against the product chute.

Still other embodiments are directed toward automated netting gatheringassemblies that include a pair of spaced apart laterally extendable andretractable netting gathering plates disposed downstream of a nettingproduct chute, wherein in operation the netting gathering plates traveltoward an axial line of netting to gather the netting material.

In particular embodiments, the assemblies can also include a pair ofpivoting netting gathering plates positioned on an opposing side of theaxial line of the netting. The pivoting netting gathering plates can beconfigured to cooperate with the laterally retractable and extendablegathering plates to converge the netting material and gather the nettingmaterial after a product held in the netting material passes by thenetting gathering plates.

Still other embodiments are directed toward netting/product chuteshaving an interior cavity and an exterior surface adapted to holdnetting thereon. The chute has a non-circular cross-sectional profile.

In particular embodiments, the chute includes an entry portion that hasa larger cross-sectional area than an intermediate portion thereof. Forexample, the chute can have an elongate funnel-like configuration. Thechute can include a mounting bracket attached thereto. The mountingbracket may have a planar substantially horizontal mounting platform anda vertical segment with a support channel configured to snugly receiveand hold a bottom portion of the product chute. The mounting bracket maybe configured as a quick disconnect to allow changeover to a differentproduct chute held on a similarly configured mounting bracket.

Yet other embodiments are directed toward a packaging apparatus forpackaging at least one discrete object in a netting material. Theapparatus includes a product table positioned downstream of a clippermechanism and a vertically extendable and retractable product holdingmember disposed downstream of the clipper mechanism proximate anupstream portion of the product table. In operation, the product holdingmember can be configured to controllably travel down while the nettingmaterial is being clipped and then controllably rise to allow theenclosed netted product to travel downstream thereof onto the producttable.

Additional embodiments are directed toward pivotable clipper assembliesfor attaching at least one closure clip to a product held in netting.The clipper assemblies include: (a) a pivotable clipper mechanism havinga clipper body configured to deliver clips to a clip window and attachthe clips to netting; and (b) a first cutting cartridge mounted to thepivotable clipper mechanism. The first cutting cartridge includes anactuation cylinder with a rod that advances and retracts a knife and ananti-rotation block attached to the rear of the knife intermediate theknife and rod to inhibit the knife and cylinder rod from rotating. Inoperation, the first cutting cartridge pivots with the clippermechanism.

In particular embodiments, the clipper assemblies may also include aproximity sensor mounted to the cartridge to provide data to control thetiming of the actuation of the cylinder to automatically controllablyadvance the knife to sever the netting.

In still other embodiments, the clipper mechanism may include a grooveformed therein. The first cartridge can include a cartridge platformconfigured to slide into the groove in the clipper mechanism to therebyreleasably mount to the clipper mechanism. In addition, the clipperassembly can include a second cutting cartridge assembly releaseablymountable to the clipper mechanism. The second cartridge can have acartridge platform configured and sized to slide into the groove in theclipper mechanism. The second cutting cartridge can include a hot knifeelement and a heat source in communication therewith. The second hotknife element can be connected to a corresponding actuation cylinder tocontrollably advance and retract. The second cutting cartridge can alsopivot with the clipper mechanism.

Yet additional embodiments are directed toward automated product pusherassemblies for pushing product through a product chute that dispensescovering material from an outer surface thereof so that the coveringmaterial receives a product discharged from the product chute. Theassemblies include: (a) a pusher head having a forward portion andaxially extending guidewalls disposed on opposing sides of the forwardportion, the pusher head configured and sized to enter into the productchute and push an object undergoing packaging through the product chute;and (b) a pusher actuation cylinder attached to the pusher head assemblyto direct the pusher head assembly to automatically and controllablylinearly travel between a downstream position and an upstream position.

Other embodiments are directed toward computer program products foroperating an automated clipped netting packaging apparatus. Theautomated packaging apparatus includes an automated product pushermechanism that advances and retracts from a product chute and anautomated clipping apparatus that applies at least one closure clip tonetting thereat. The computer program product includes a computerreadable storage medium having computer readable program code embodiedin the medium. The computer-readable program code includes: (a) computerreadable program code that automatically controllably actuates a pusheractuation cylinder to push a product pusher in a downstream direction;and (b) computer readable program code that automatically controllablyactuates a clipper mechanism to position a clipping apparatus in aclipping position in response to product pushed by the product pusherout of the product chute covered in netting.

In particular embodiments, the computer program product can also includecode that: (a) automatically controllably actuates netting gatheringplate actuation cylinders to laterally translate the plates toward theclipper mechanism; and/or (b) automatically controllably actuates apackage holding member to raise the holding member above a productsupport floor to maintain a product held in netting in alignment withthe clipper mechanism.

These and other objects and/or aspects of the present invention areexplained in detail in the specification set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of an apparatus/system used toautomatically advance objects through a product chute and thenautomatically apply a clip(s) via a clipper mechanism according toembodiments of the present invention.

FIG. 2 is a front view of the device shown in FIG. 1 according toembodiments of the present invention.

FIG. 3 is a left side view of the device shown in FIG. 1 according toembodiments of the present invention.

FIG. 4 is a right side view of the device shown in FIG. 1 according toembodiments of the present invention.

FIG. 5 is a top view of the device shown in FIG. 1 according toembodiments of the present invention.

FIG. 6 is rear view of the device shown in FIG. 1 illustrated with thecontrol enclosure door removed according to embodiments of the presentinvention.

FIG. 7 is an enlarged top view of a product transfer zone that can forma portion of the device shown in FIG. 1 according to embodiments of thepresent invention.

FIG. 8 is a front view of a human interface station suitable for usewith the device shown in FIG. 1 according to embodiments of the presentinvention.

FIG. 9 is an enlarged top view of a portion of the device shown in FIG.1, similar to that shown in FIG. 5, but shown with certain screens orhousing components removed for clarity according to embodiments of thepresent invention.

FIG. 10 is a side perspective view of a product infeed conveyor (withthe conveyor belt removed) that may be suitable for use in the device ofFIG. 1 according to embodiments of the present invention.

FIG. 11 is a front view of the conveyor shown in FIG. 10.

FIG. 12A is a partial front perspective view of the device shown in FIG.1 illustrating the conveyor shown in FIG. 10 with an exemplary conveyorbelt in place according to embodiments of the present invention.

FIG. 12B is a top view of an exemplary flooring surface according toembodiments of the present invention.

FIG. 13 is a side view of a product chute according to embodiments ofthe present invention.

FIG. 14 is a side perspective view of the chute shown in FIG. 13according to embodiments of the present invention.

FIG. 15 is an enlarged perspective view of the device of FIG. 1illustrating a product pusher mechanism in a retracted position upstreamof the product transfer zone and illustrates a pusher head having a flatproduct pusher plate according to embodiments of the present invention.

FIG. 16 is a front view of the product pusher mechanism of FIG. 15 in anextended position downstream of the product transfer zone andillustrates a pusher head having a “V” shaped product pusher plateaccording to embodiments of the present invention.

FIG. 17 is a front view of the product pusher mechanism of FIG. 15 in anextended position downstream of the product transfer zone according toembodiments of the present invention.

FIG. 18 is a side perspective view of a pusher head according toembodiments of the present invention.

FIG. 19 is a side perspective view of an alternative pusher headaccording to embodiments of the present invention.

FIG. 20 is a side perspective view of yet another alternative pusherhead according to embodiments of the present invention.

FIG. 21 is an enlarged partial front view of the downstream portion ofthe device of FIG. 1 illustrating, inter alia, a clipper mechanism, aretractable package holding member and product table according toembodiments of the present invention.

FIG. 22 is a top view of the portion of the device shown in FIG. 21according to embodiments of the present invention.

FIG. 23 is a left side view of the downstream portion of the deviceshown in FIG. 22 according to embodiments of the present invention.

FIG. 24 is a side perspective view of a brake assembly according toembodiments of the present invention.

FIG. 25 is a top view of the brake assembly shown in FIG. 24.

FIG. 26 is a right side view of the brake assembly shown in FIG. 24.

FIG. 27 is an enlarged left side view of the downstream portion of thedevice shown in FIG. 1 illustrating the brake assembly in an exemplaryposition and showing the clipper mechanism retracted according toembodiments of the present invention.

FIG. 28 is an enlarged left side view of the downstream portion of thedevice shown in FIG. 1 similar to the view shown in FIG. 27, butillustrated with the clipper mechanism in clipping position and withgathering plates cooperating to gather the covering material accordingto embodiments of the present invention.

FIG. 29 is a front view of a portion of the device shown in FIG. 1,illustrating the product chute with netting thereon and a covering(netting) gathering plate(s) positioned proximate the discharge end ofthe chute according to embodiments of the present invention.

FIG. 30 is an opposing side view of the gathering plates shown in FIG.29 which shows them positioned proximate the discharge end of theproduct chute according to embodiments of the present invention.

FIG. 31 is a front perspective view of a retractable (pivotable) clipperassembly with gathering plates thereon according to embodiments of thepresent invention.

FIG. 32 is a left side view of the device shown in FIG. 31.

FIG. 33 is a front view of the device shown in FIG. 31.

FIG. 34 is a right side view of the device shown in FIG. 31.

FIG. 35 is a rear view of the device shown in FIG. 31.

FIG. 36 is an enlarged left side view of the device shown in FIG. 31according to embodiments of the present invention.

FIG. 37 is an enlarged left side view of the device shown in FIG. 31similar to that shown in FIG. 36 but illustrated with the left diesupport removed for clarity.

FIG. 38 is an enlarged left side view of the device shown in FIG. 31,similar to FIG. 36, but illustrating the gate closed with coveringmaterial gathered prior to application of a clip according toembodiments of the present invention.

FIG. 39 is an enlarged left side view of the device shown in FIG. 31,similar to that shown in FIG. 38, but also illustrating a clip punchattaching a clip to gathered covering material (netting) according toembodiments of the present invention. FIG. 39 also illustrates acartridge mounted modular cutting tool (knife blade) held on theclipping mechanism in a retractable position ready to sever the coveringmaterial after the clip is attached according to embodiments of thepresent invention.

FIG. 40 illustrates the cartridge with the cutting tool extended so thatthe knife can penetrate the covering material according to embodimentsof the present invention.

FIG. 41 is an enlarged partial front view of the clipper mechanism shownin FIG. 31, similar to that shown in FIG. 33, but illustrating the knifein operative position according to embodiments of the present invention.

FIG. 42 is a right side view of an interchangeable modular secondcutting cartridge providing a hot-knife cutting option according toembodiments of the present invention.

FIG. 43 is a top view of the hot-knife cutting cartridge shown in FIG.42.

FIG. 44 is a side perspective view of the cartridge shown in FIG. 42.

FIG. 45 is a right side view of the cutting cartridge shown in FIG. 42,but illustrated with the anvil removed for clarity according toembodiments of the present invention.

FIG. 46 is a photograph of an exemplary object automatically packaged inclipped netting employing apparatus and devices described aboveaccording to embodiments of the present invention.

FIG. 47 is a flow chart of operations that can be carried out accordingto embodiments of the present invention.

FIG. 48 is a block diagram of a data processing system/computer programaccording to embodiments of the present invention.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention will now be described more fully hereinafter withreference to the accompanying figures, in which embodiments of theinvention are shown. This invention may, however, be embodied in manydifferent forms and should not be construed as limited to theembodiments set forth herein. Like numbers refer to like elementsthroughout. In the figures, certain layers, components or features maybe exaggerated for clarity, and broken lines illustrate optionalfeatures or operations, unless specified otherwise. In addition, thesequence of operations (or steps) is not limited to the order presentedin the claims unless specifically indicated otherwise. Where used, theterms “attached”, “connected”, “contacting”, “coupling” and the like,can mean either directly or indirectly, unless stated otherwise. Theterm “concurrently” means that the operations are carried outsubstantially simultaneously.

In the description of the present invention that follows, certain termsare employed to refer to the positional relationship of certainstructures relative to other structures. As used herein, the term“front” or “forward” and derivatives thereof refer to the general orprimary direction that the clips travel toward a target product forclosure and/or the direction that the target filled or stuffed productin casing material travel; this term is intended to be synonymous withthe term “downstream,” which is often used in manufacturing or materialflow environments to indicate that certain material traveling or beingacted upon is farther along in that process than other material.Conversely, the terms “rearward” and “upstream” and derivatives thereofrefer to the directions opposite, respectively, the forward anddownstream directions.

The present invention is particularly suitable for applying closureclips to discrete objects held in a covering material. The coveringmaterial may be natural or synthetic and may be a casing material thatcan be sealed about a product or may be netting. The casing can be anysuitable casing (edible or inedible, natural or synthetic) such as, butnot limited to, collagen, cellulose, plastic, elastomeric or polymericcasing. The term “netting” refers to any open mesh material formed byany means including, for example, knotted, braided, extruded, stamped,knitted, woven or otherwise. Typically, the netting is configured so asto be stretchable in both axial and lateral directions.

Netting or other covering material may be used to package discrete meatproducts such as loafs of meat, boned ham, spiral sliced ham, debonedham, turkey, turkey loafs held in molds, or other meat or items directlyor with the items held in subcontainers and/or wraps such as molds,trays, boxes, bags, absorbent or protective sheets, sealant, cans andthe like. Other embodiments of the present invention may be directed topackage other types of food such as cheese, bread, fruit, vegetables,and the like. Examples of non-food items that may be packaged usingembodiments of the present invention include living items such as flora,fauna, trees, and the like, as well as inanimate objects. Additionalexamples of products include discrete, semi-solid or solid non-flowableobjects such as firewood, pet food (typically held in a container if thewet type), recreational objects (such as balls), or other solid orsemi-solid objects. The product may be a packaged for any suitableindustry including horticulture, aquaculture, agriculture, or other foodindustry, environmental, chemical, explosive, or other application.Netting may be particularly useful to package ham or turkeys,manufactured hardware such as automotive parts, firewood, explosives,molded products, and other industrial, consumable, and/or commodityitem(s).

Generally stated, embodiments of the present invention are directed atautomating packaging of piece goods or discrete items by forcing themthrough a product chute and wrapping or enveloping the objects at theother end of the chute in a covering material, such as netting, and thenautomatically clipping the covering material with a closure clip orother attachment means to close the covering and hold the object orobjects inside of the covering material. As noted above, clippers areavailable from Tipper Tie, Inc., of Apex, N.C. Examples of suitableclips include metallic generally “U”-shaped clips available from TipperTie, Inc., in Apex, N.C. Other clips, clip materials and clipconfigurations or closure means may also be used.

FIG. 1 illustrates an exemplary automatic clipping packaging apparatus10 according to embodiments of the present invention. In the embodimentshown, the apparatus 10 can be described as a horizontal automaticclipping packaging apparatus as the product is primarily moved,processed, clipped and packaged in a horizontal plane. However, certaincomponents, features or operations may be oriented and/or carried out inother planes or directions and the present invention is not limitedthereto. As shown, the apparatus 10 includes a product pusher assemblyor mechanism 20, a product chute 30, and a clipper 40. It is noted thatthe clipper 40 may be referred to herein as a clipper apparatus, clippermechanism, and/or clipper assembly, but each term may be usedinterchangeably with the others. As shown, the apparatus 10 mayoptionally include an infeed conveyor 50.

FIG. 2 illustrates the front view of the apparatus 10 shown in FIG. 1.The arrow indicates the direction of product flow as toward the productchute 30 and clipper 40. Thus, although the downstream direction 10 d isshown as moving from right to left (with the upstream direction 10 u) inthe opposing direction, the apparatus can be oriented to run left toright or in a direction that is in or out of the paper. FIG. 2 alsoillustrates a human machine interface (“HMI”) station 55 that housesoperational switches or components that an operator can access tooperate the apparatus or system 10. The apparatus 10 includes a producttransfer zone 60, which is the location where a product (or products) ispositioned, intermediate the product pusher assembly 20 (in theretracted position) and the product chute 30, and substantially alignedwith the internal cavity 30 c (FIG. 14) of the product chute 30. Thispositioning of the product in the flow path and/or alignment with theproduct chute cavity 30 c can be carried out substantially automaticallyas will be discussed further below. However, a target product undergoingpackaging can also be manually introduced or placed into the flow pathand subsequently processed as in an automatic in-feed operation.

In operation, the product pusher assembly 20 linearly retracts andadvances to push a product through the product chute 30 so that theproduct is positioned proximate the clipper 40 and then retracts to aresting state upstream of the product transfer zone 60. As describedabove, a sleeve of covering material can be positioned about theexternal surface of the product chute 30 and configured to be drawndownstream thereof so as to automatically encase the product as theproduct emerges from the discharge end 30 d of the product chute 30. Asupplemental sleeve material holder may also be used if desired insteadof placing the sleeve of casing material on the product chute. Thesupplemental sleeve holder can be configured to surround a downstreamportion of the product chute (not shown). The sleeve of coveringmaterial may be sized to stretch to substantially conform to theexternal wall or surface of the product chute 30 or may be more looselyheld thereon. The cavity of the product chute 30 c may be sized tosnugly contact or squeeze opposing portions of the product (side to sideand/or top to bottom) as the product is pushed therethrough or may beoversized with respect to the product so that the product looselytravels therethrough.

In operation, the sleeve of covering material may be clipped, welded,fused, knotted or otherwise closed at a leading edge portion thereof.When the product exits the product chute 30, it is held in the coveringmaterial as the covering material is drawn downstream. The coveringmaterial is typically loaded onto the product chute 30 and the leadingedge portion closed before the product chute 30 is mounted to theapparatus 10.

The product pusher assembly 20 has a pusher head 20 h that contacts theproduct and pushes the product downstream through the product chute 30.After the product exits the product chute 30, the downstream portion orleading edge of the product in the covering material can be held inposition proximate the clipper 40. As shown in FIG. 3, in certainembodiments, the product can be held by positioning a verticallyretractable product holding member and/or clamp bar 75 to inhibit theproduct from migrating downstream thereby holding the product in thecovering material between the product holding member 75 and thedischarge end of the product chute 30 during the clipping operation.

FIG. 3 illustrates the discharge end portion of the product chute 30that is positioned proximate and upstream of the clipper 40. The productpusher assembly 20 has a pusher head 20 h that is adapted to contact theproduct. As shown, the pusher head 20 h may be configured tosubstantially fill the entire cross-sectional width of the product chutecavity 30 c as the pusher head 20 h approaches and/or exits thedischarge portion of the product chute 30 d. The clipper 40 isconfigured to reside in a retracted position out of the product flowregion to allow the enclosed product to pass unimpeded until the productrests against the product-holding member 75.

As shown, in FIGS. 3 and 4, the clipper 40 can be pivotably mounted 40 pto a frame and sized and configured to automatically controllablyactuate to advance into a clipping position after the product is inposition downstream thereof and then clip the covering material andretract to await to clip the next covering material for the nextenclosed product. The clipper 40 may operate in response to data from aproximity sensor that is positioned to detect when a product is readyfor clipping and provide the data to a controller or processor. Theproximity sensor may be positioned at any suitable place to indicatewhen the product is in position. The proximity sensor can be an optical(infrared, photosensor, or the like), a hall-effect sensor, a magneticsensor, an inductive sensor, and/or any other suitable sensor. FIG. 4also illustrates that the clipper 40 can be attached to a clipperrotation rotary actuator 40 _(RA) that can control the movement of theclipper 40 during use. FIG. 4 also shows the control housing 88.

FIG. 5 illustrates that the product pusher assembly 20 can include aproduct pusher cylinder 21 and two product pusher guide rods 22, 23,respectively. The product pusher guide rods 22, 23 can be positioned onopposing sides of the pusher cylinder 21 and help to stabilize (providean anti-rotation structure) for the pusher head 20 h as the pusher head20 h travels outside the product chute 30.

FIG. 6 illustrates the apparatus 10 with the control housing 88 door orpanel removed. As shown, the control housing 88 can hold system valves,pressure transducers, actuator controls, a processor that directs theautomated operations of the apparatus 10 (which may also be held intotal or partially in the Human Machine Interface or “HMI” 55, FIG. 2)and other electronic, software and/or mechanical equipment as will beunderstood by one of skill in the art.

FIG. 7 illustrates the product transfer zone 60 with a ceiling or lid 60c that overlies the floor 60 f and a sensor 61 held in the ceiling 60 c.The underlying product pusher assembly 20 is shown deployed with thepusher head 20 h extended into the product chute 30. The ceiling 60 cmay be pivotably mounted 60 p to the frame of the apparatus 10 to allowan operator easier access to the transport zone 60 for clearing misfeedsand the like. The sensor 61 can be an ultrasonic sensor configured toidentify when a product is in a suitable deployable position in theunderlying space of the product transfer zone 60. This data can be fedto a controller that can then timely activate the actuation cylinder toadvance the product pusher assembly 20. In operation, if an expectedproduct is not delivered to the product transfer zone 60 within apredetermined time, a timing circuit (typically included in the machinecontrol logic program code) can automatically stop the infeed conveyor50. An operator can restart the apparatus 10 by depressing the startpushbutton.

As shown in FIG. 5, the apparatus 10 may include another sensor 31positioned proximate the receiving end of the product chute 30. Thesensor 31 is configured to confirm that the product chute 30 is inoperative position. When a product 100 is detected in the transfer zone60, the activation of the product pusher assembly 20 may also be basedon whether the product chute 30 is determined to be in proper positionusing data from the sensor 31, typically positioned on the framethereat. An exemplary sensor is a two-part magnetic switch, one part canbe positioned on a mounting bracket 31 b attached to a chute bracket 30b as shown in FIG. 14 and the other part held on the mounting frame 10f. When the two matable parts of the switch 31 engage, the chute 30 isdetermined to be in proper position. Other types and/or additionalsensors may also be used as suitable as is known to those of skill inthe art.

A controller/processor (such as a Programmable Logic Controller) may beconfigured to monitor a signal from this sensor 31 and deactivate theproduct pusher assembly (release cylinder pressure) automaticallywhenever a product chute 30 position-error is noted at any time duringthe process. The signal can be automatically monitored through a SafetyCircuit Module. If the product chute 30 is missing or out of position,the apparatus 10 can be held in a low energy state that removes power toair supplies and controls to inhibit machine operation. To reinitiatethe procedure, an operator may press a restart or reset button. Incertain embodiments, the clipper 40 may be operated on override evenwhen the chute 30 is absent. Once the product chute 30 is in locationand the stop is reset, power air can be applied to the machine controlvalves and electric power can be applied to the control (PLC) outputs.After the PLC determines the positions of the moveable components, suchas the product pusher assembly 20, the clipper 40, the product holdingmember 75, and the like, an automatic reset can be performed and thosecomponents automatically moved to a respective home position as needed.

FIG. 8 illustrates the HMI can include a start button 57, an emergencystop button 56, a reset button 55 ₁ and a clipper only activation button55 ₂. The HMI can also include two pressure regulator 58 ₁, 59 ₁ andcorresponding gages 58 ₂, 59 ₂, the pressure monitors can be for theretractable product holding member 75 (FIG. 3), (which may be describedas a product clamp bar) and one for a retractable brake system 90 (FIG.24), typically used to selectively apply brake pressure to the coveringmaterial proximate the discharge end portion of the product chute 30.

As shown, the apparatus 10 may be configured to allow the clipper 40 tooperate irrespective of the upstream devices using the clipperpushbutton 55 ₂ instead of the apparatus start pushbutton 57. The HMIcan also include an emergency stop 56 and reset 55 ₁ pushbutton or othertype of switch as shown.

FIG. 9 illustrates a product 100 on the floor 50 f of the conveyor 50and positioned in the product transfer zone 60. The product 100 isstopped by a product stop plate 60 s from progressing out of the outerperimeter of the chute 30 so that the product is in communication withthe inlet portion of the chute 30 and so that the product pusherassembly 20 will be able to push the product 100 axially downstreamthrough the product chute 30 substantially about the chute axis 30 a.

It is noted that in lieu of and/or with the conveyor 50, other movingfloors or product advancement systems may be used. For example, rollers,rolling bars, belts or drives that progress trays or other supportmembers and the like. In addition, the moving floor may be angularlyoriented to travel up, down, or otherwise to advance the product to theproduct transfer zone 60. In addition, the apparatus 10 can include anautomated continuous advancement system with discrete product(s)separated at desired intervals on the moving floor to serially introduceproduct for packaging to the chute 30. In certain embodiments, themoving floor can include partitions, channels, or other spacerconfigurations to hold the product(s) in desired alignment on the movingfloor so that, when the proximity sensor indicates the product ispresent, the partition or channel provides the desired product stop.

For groups of objects, manual or automated bins or feeders canaccumulate the desired amount of grouped objects upstream and place themtogether on the moving floor (not shown). In other embodiments, anautomated counter can be used to count the number of products that passa target location or enter the transfer zone 60 so that a desired numberof products are accumulated in the transfer zone 60 and then activatethe product pusher assembly 20 (not shown).

FIG. 9 also illustrates that the pusher head 20 h can be configured witha product pusher plate 20 p that is adapted to contact the product 100(such as food) as the pusher assembly 20 extends forward. The pusherhead 20 h can also include axially extending guidewalls 20 w ₁, 20 w ₂.The pusher head 20 h can be sized and configured to substantially fillthe chute cavity 30 c to thereby inhibit objects from attempting tomigrate downstream during the pushing operation. The pusher plate 20 pis shown in FIG. 9 as a forward portion adapted to contact the productwhich, when viewed from the top, comprises side portions that angularlyconverge to a peak and/or a substantially “V” shape, otherconfigurations and shapes may also be used as will be discussed furtherbelow. FIG. 9 also illustrates the assembly 20 and/or the product pusherhead 20 h in a home or resting position.

FIGS. 10 and 11 illustrate an example of a conveyor system 50 (with thefloor and/or belt removed). The system 50 includes a DELRIN conveyorfloor support 50 s, belt drive sprockets 56, air motor 57 and gear box58 that automatically advance the conveyor floor 50 f. A drive sprocketchain or belt 58 b is shown in position in FIG. 11 attached to a drivemember 56 d connecting the sprockets 56 and the gearbox 58. The arrowsin FIG. 10 represent the direction of movement. The conveyor floor 50 fmaterial may be an open mesh, interlocking material. FIG. 12Billustrates an example of a commercially available conveyor beltmaterial comprising an interlaced composite material and FIG. 12Aillustrates the conveyor floor/belt 50 f in position on the conveyorsystem 50. Generally stated, in the embodiment shown, the conveyor floor50 f is driven by a series of sprockets 56 that engage the weave and/orunderside of the conveyor floor 50 f. A radial piston air motor 57drives the conveyor floor 501 through a speed reduction gearbox 58.Power is transmitted to the conveyor drive roller via a chain andsprocket configuration.

FIG. 13 illustrates a side view of the product chute 30 held on amounting bracket 30 b. As shown, the product chute 30 can be an elongateproduct chute. The product chute 30 can include a larger front-endcavity area 30 a (shown as a funnel-like shape) relative to theintermediate and/or discharging portion 30 d, i.e., the chute cavity 30c narrows in the pushing/product travel direction. Thus, the productchute 30 can include a primary body and a larger upstream guide portionthat narrows into the shape of the primary body. The chute 30 may beformed as a unitary member or a series of attached members (not shown).The chute 30 can include a lifting handle 30 h to facilitate removal andinstallation. In operation, a supply of covering material (see, e.g.,FIG. 46) can be placed on or about the chute 30, arranged to surroundthe exterior surface of at least a portion of the product chute 30 andextend in tension in the downstream direction to cover the product(tenting in the axial direction) as the product exits the discharge endportion of the product chute 30 d. In certain embodiments, the coveringmaterial is configured and sized to stretch in at least the lateraldirection and typically in both the lateral and axial directions as itis held on and dispensed from the product chute 30.

The product chute floor 30 f may be a stationary floor as shown in FIG.14. It is also noted that the product chute 30 may include a movingfloor such as those types described above with respect to the infeedfloor configurations. The chute 30 may be sized relative to the product100 so that the product 100 extends across a major portion of the widthof the cavity, and in certain embodiments, extends across at least about75% of the width of the cavity. In certain embodiments, the product 100and chute cavity 30 c are sized so that the sides and/or top and bottomof the product 100 are pressed against the sidewalls of the cavity asthe product is pushed therethrough. The product chute 30 may comprisestainless steel and be coated with a friction reducing material such asTEFLON. Lubricants may also be disposed on the inner surface(s) of theproduct chute 30.

In certain embodiments, the product chute 30 has a cross-sectionalprofile that is non-circular. As shown in FIG. 3, the product chute 30may be configured with a planar top and/or bottom portion andsemi-circular side portions. Other cross-sectional profileconfigurations may also be used including, but not limited to, circular,oval, triangular, rectangular, square and the like.

As shown in FIGS. 13 and 14, the product chute 30 can be configured tomount on a mounting bracket 30 b that fits into a frame on the apparatus10. The mounting bracket 30 b may also hold the safety proximity orinterlock sensor using bracket 31 b as discussed above. The bracket 30 bcan include a planar platform 30 b ₁ (typically mounted substantiallyhorizontal) that is connected to an upwardly extending segment 30 b ₂(typically substantially vertical). The upwardly extending segment 30 b₂ can include a center receiving channel portion 30 b ₃ that is sizedand configured to receive the contour of the bottom portion of the chute30 (i.e., may be sized and configured to substantially correspond withthe profile of a lower portion of the product chute).

The mounting bracket 30 b can be configured to relatively easily attachto and be removed from the frame of the apparatus 10 so as to bereleasably mountable thereto. The mounting bracket 30 b can hold theproduct chute 30 in alignment with the clipper mechanism 40 downstreamand the product pusher mechanism 20 upstream. In certain embodiments,the system 10 can include a first product chute and a respective firstmounting bracket 30 b and a second product chute 30 releasably mountableto the apparatus frame 10 at the same position (interchangeable chutes)using a respective second mounting bracket 30 b that can be configuredsubstantially the same as the first mounting bracket 30 b. In otherembodiments, the product chute 30 can be lifted off of the mountingbracket 30 b (leaving the mounting bracket in place) and another chute30 placed thereon. The second product chute may be sized and configuredthe same as the first product chute 30 and loaded with a second supplyof covering material. The covering material may be the same as that ofthe first product chute or different. Thus, the respective first andsecond mounting brackets 30 b can be configured as quick disconnectcomponents (merely loosening and/or releasing attachment hardware) toallow the first and second product chutes 30 to be interchanged on thesystem 10 in under 5 minutes, and more typically in under about 2minutes, to allow an operator to employ at least one of a different sizeproduct chute, a different configuration product chute, differentpackaging material dispensed by the product chute.

In other embodiments, a plurality of chutes 30 can be mounted on asliding or movable track that can serially move a selected chute out ofand/or into the operative position (not shown). The plurality of chutes30 may be positioned side to side or above and below (verticallystacked) each other, mounted on a carousel, and the like so as toautomatically move into and out of position. In operation, an operatoror an autoloader can place a sleeve of covering material on one or morechutes 30, select the order of presentation (based on the type ofproduct being dispensed and/or the type of covering material desired),and proceed to move the chutes serially into operative position so as tobe aligned with the product pusher assembly 20 and the clipper 40. Inthis manner, the apparatus 10 can be preloaded or reloaded with coveringmaterial limiting any downtime associated therewith.

FIG. 15 illustrates the product pusher assembly 20 in a retractedposition while FIGS. 16 and 17 illustrate the product pusher assembly 20in extended positions. The chutes 30 are shown translucent for viewingof the spatial relationship with components of the pusher assembly 20.As shown in FIG. 16, the product pusher mechanism 20 is configured tolimit the travel of the pusher head 20 h so that at least a portion ofthe pusher head 20 h remains inside the product chute 30 at afurthermost operative extension position (extended position) of theproduct pusher mechanism 20. The pusher head 20 h exits the chute agreater length in the embodiment shown in FIG. 16 relative to that shownin FIG. 17. In FIG. 16, the forward portion of the pusher head 20 hpasses the downstream of the gathering plates while in FIG. 17, thepusher head stops short of the most downstream gathering plate (thegathering plates will be discussed further below). In operation, thepusher head 20 h is configured to push the product from the dischargeend of the chute 20 d so that the covering material extends a sufficientdistance therefrom to allow an automated clipping operation to becarried out.

As described above, the product pusher mechanism 20 comprises a pair ofspaced apart elongate guidewalls 20 w ₁, 20 w ₂ positioned on opposingsides of the forward portion of the pusher head 20 h to help guide thepusher head in the product chute 30. The guidewalls 20 w ₁, 20 w ₂ mayhave a length that is less than the length of the product chute 30. Theguidewalls 20 w ₁, 20 w ₂ may each connect to a guide rod 23, 22,respectively. The guiderods 22, 23 may be symmetrically arranged withrespect to the intermediately located pusher cylinder 21. As shown inFIGS. 1 and 5, the product pusher assembly 20 can operate using afluid-actuated cylinder 21 (typically a pneumatic cylinder) that islongitudinally mounted on the apparatus 10 in the axial direction. Thecenterline of the cylinder 21 may be aligned with the product chutecenterline 30. The two guide rods 22, 23 can be stainless steel guiderods mounted in a linear ball bearing block assembly. As noted above,the guide rods 22, 23 can act as an anti-rotation stabilizer for theproduct pusher assembly 20 and/or help guide the assembly 20 to travelin a substantially straight line through the product chute 30 as theassembly 20 travels repetitively through extended and retractedconfigurations.

FIG. 16 and FIG. 18 illustrate the pusher head 20 h with a substantiallyplanar forward portion 20 p (which may be formed by a plate) while FIG.17 and FIG. 20 illustrate the pusher head 20 h with an inverted “V”configuration and/or when viewed from the top, the forward portioncomprises side portions that angularly converge to a valley 20 v. FIG.20 illustrates the pusher head 20 h with a “V” configuration and/or withside portions that converge to a peak 20 pk. The peak or valley may besymmetrically or asymmetrically positioned on the contacting portion ofthe pusher head 20 h. The shape of the product-contacting portion 20 pof the pusher head 20 h may influence the orientation of (typicallyattitude) of the product inside the netting as it exits the chute 30.

Referring to FIGS. 18-20, the guidewalls 20 w ₁, 20 w ₂ and/or theforward portion 20 p of the pusher head 20 h may be formed of and/orcoated with a non-stick material (and/or lubricant) such as TEFLON. Inparticular embodiments, such as for packaging of meat, the guidewalls 20w ₁, 20 w ₂ may be formed of ACETYL while the forward portion 20 p isformed of stainless steel. FIGS. 18 and 19 illustrate the guidewalls 20w ₁, 20 w ₂ abutting the rear surface of the forward portion 20 p of thepusher head 20 h while FIG. 20 illustrates that the guidewalls 20 w ₁,20 w ₂ may be separated a distance from the forward portion 20 p.

FIG. 21 illustrates a downstream portion of the apparatus 10 accordingto certain embodiments of the present invention. The discharge endportion of the product chute 30 d terminates proximate the clipper 40.The product-holding member 75 (i.e., product clamp bar) canautomatically be moved into position (shown as retractable in thevertical direction in FIG. 21) by actuating a clamp drive cylinder 75 cand thereby block the product from moving further downstream. Theholding member 75 may be configured to actuate to its operative holdingposition prior to retraction of the product pusher assembly 20 and toclamp onto the encased product to inhibit the product from migratingback into the chute as the product pusher head 20 h is retracted. Theholding member 75 can also hold the encased product so that the upstreamcovering material is relatively firmly or tightly held proximate theclipper 40 and/or facilitate centering the covering material during thegathering and clipping operations.

In certain embodiments, the no mal position of the member 75 is abovethe horizontal product plane. This position allows the product to passunder the member 75 prior to actuation. Alternatively, the member 75 canreside laterally offset from the travel path and pivot, translate orswing into position. In yet other embodiments, the member 75 cannormally reside retracted under the floor of the travel path. In anyevent, after a clipping operation, the holding member 75 can beautomatically moved to allow the encased product to move downstream tothe product table 76. The clipped encased product may be manually moveddownstream or automatically moved downstream using the next product topush it onto the adjacent table or by configuring the adjacent travelfloor as a moving floor.

The actuation of the cylinder 75 c can be controlled by the PLC usingproximity sensors and operation feedback as will be understood by one ofskill in the art. The product holding member 75 can position the productso that the trailing edge portion of the covering proximate the encasedproduct is held proximate a clip window (40 w, FIG. 31) associated withthe clipper 40. The product table 76 may be stationary. In otherembodiments, the product table 76 may include a traveling floor thatadvances the packaged product to another processing or subsequentworkstation (not shown).

The clipper 40 can include a curvilinear clip rail or channel 41 that isin communication with the clip window 40 w to automatically supply clipsto the underlying covering material. As shown in FIGS. 21 and 23, theclipper 40 can be positioned proximate a covering material gatheringsubassembly 140 comprising a plurality of gathering plates 141, 142,143, 144 (FIG. 23) that are configured to automatically gather a portionof the tubular or sleeve of covering material to form the material intoa rope-like and/or compressed configuration in preparation for receivingthe clip(s) thereabout. The gathering plates 141-144 are configured togather or compress the covering material that extends between theclipper 40 and the product chute discharge end portion 30 d. Pairs ofcooperating plates (i.e., 143, 141 and 142, 144) can be positionedacross the product travel path to retractably travel toward each other,substantially orthogonal to the direction of product travel, to gatherthe covering material therebetween. In certain embodiments, gatheringplates on the first side of the travel path may be mounted to theclipper 40 as will be discussed below and, hence be described as clippergathering plates 143, 144. In particular embodiments, the gatheringplates 141, 142 disposed on the opposite side of the travel path may bedescribed as netting gathering plates for clarity of description. Abrake assembly 150 may be configured to automatically deploy toselectively apply a force against the chute 30 to hold the coveringmaterial during the clipping operation as will be discussed furtherbelow.

Once the covering material is gathered, a clip or clips can be appliedto secure the encased product in the covering material. The coveringmaterial can then be severed to release the encased product in theclipped package. Typically, two clips are applied substantiallyconcurrently proximate to each other using a dual clipper 40 so that oneclip closes the trailing edge of the covering material forming a firstencased package and the other closes a leading edge of the coveringmaterial forming the next encased package. The clipped configuration ofthe covering material encasing the product may be configured tosubstantially conform to the shape of the enclosed product(s) or may bemore loosely configured (see, e.g., FIG. 46 which illustrates a hamencased in clipped netting).

FIG. 23 illustrates the retractable product-holding member 75 andcorresponding actuation cylinders 75 c. FIG. 23 also illustrates thecovering material gathering subassembly 140 with the plurality ofgathering plates 141, 142, 143, 144. In operation, the first set ofgathering plates 143, 144 (shown as two, but more or less can be used)can be positioned-on a first side of the product travel path while asecond set 141, 142 (again shown as two, but more or less can be used)on the opposing side of the travel path. After the product moves by (andis stopped by the product-holding member 75), the clipper 40 moves intoposition with its actuation cylinder (41, FIG. 31) which also moves thefirst set of gathering plates 143, 144 toward the centerline of thetravel path and a second actuation cylinder 147 can move the second set141, 142 toward the centerline of the travel path. The actuationcylinder 147 can be configured as a vaned rotary actuator and the term“actuation cylinder” is used generically to indicate any type ofautomatically moveable actuation member. The first set 143, 144 may beconfigured to reach the centerline first and force the covering materialtogether through fingers 144 f ₁, 144 f ₂, 143 f ₁, 143 f ₂ withinclined surfaces that angle together toward the center gap space 145.The opposing gathering plates 141, 142 can then extend to trap thecovering material therebetween. The first and second set of gatheringplates may be timed, configured with different extension strokes and/oractuation speed to allow the first set 143, 144 to arrive at thecenterline first.

In certain embodiments, the first set of gathering plates 143, 144 aremounted to the clipper 40 (i.e., clipper gathering plates) and move inconcert therewith. The clipper 40 can be pivotally mounted 40 p (FIGS.27, 32) to the apparatus 10 to be retractable and controllably move inand out of operative position. As the clipper 40 is rotated intoposition, the clipper gathering plates 143, 144 automatically start thegathering operation. The opposing plates 141, 142 may be configured tolaterally linearly translate into and out of operative position (usingactuator 147). Referring to FIGS. 23, 27 and 28, the opposing plates141, 142 may have a different profile than those of the clipper-mountedplates 143, 144. As shown, the lower portion thereof may be curvilinearand extend inwardly a shorter distance than the fingers 143 f ₁, 143 f₂, 144 f ₁, 144 f ₂ of the opposing plates 143, 144. Actuator 146 can beused to deploy a gate member (165, FIG. 36) as will be discussed furtherbelow.

As shown by the arrow illustrating travel direction in FIG. 27, theopposing plates 141, 142 can be actuated to move toward the axialcenterline (shown as the “a” centerline which extends into and out ofthe paper). In certain embodiments, each gathering plate 141-144 can bemounted so that in operative position they are horizontally andvertically aligned with the corresponding centerlines of the productchute cavity 30 c. FIG. 27 also illustrates the clipper 40 in aretracted position (pivotally moved out of the operative position).

FIG. 28 illustrates the clipper 40 in operative position with theclipper gathering plates 143, 144 extended and residing proximate theopposing gathering plates 141, 142 with the extended configuration ofeach gathering late leaving a gap space 140 g where the convergedcovering material 100C extends through. The clipper 40 can then deliverthe clip or clips to the converged material at the clip window 40 w(FIG. 31) located intermediate the clipper gathering plates 143, 144.

FIGS. 24-26 illustrate an example of a brake assembly 150 for resistingthe downstream pull of the covering material by pressing a portion ofthe sleeve of covering material against the downstream portion of thechute 30. In operation, the brake assembly resists the dispensing ofcovering material off the product chute 30 as the covering material isbeing pulled off the chute in response to a product captured in thecovering material upon discharge from the product chute 30. As shown,the braking assembly 150 can include a pair of spaced apart arms 150 a₁, 150 a ₂ that may move substantially in concert. The arms each includeat least one gripping member 152, 153, respectively. The grippingmembers 152, 153 are configured to apply pressure against opposing sidesof the exterior surface of the chute 30 (the arms may alternatively oradditionally be configured to move against opposing top and bottomportions of the chute). The arms 150 a ₁, 150 a ₂ can be mounted to acommon frame member 150 f. A cylinder 153 can extend between the arms150 a ₁, 150 a ₂ to cause the arms to controllably pivot toward and awayfrom each other. A spring or other biasing component (which may beinternal to the cylinder) may be used to maintain the arms in a normallyopen position (not contacting the product chute 30). Fluid can beapplied to actuate the cylinder 153.

Thus, for example, when power is removed from the apparatus 10 (such asupon removal of the chute 30), no power air will be needed to force thearms apart. In contrast, application of air (or other fluid) to thecylinder 153 will retract the arms toward each other so that thegripping members 151, 152 contact the covering material and rest againstthe chute 30. FIG. 27 illustrates the gripping members 151, 152 inposition adjacent the sidewalls of the chute 30. The brake assembly 150can inhibit an excessive quantity of covering material from being pulledoff the chute 30 during product insertion into the covering. The brakeassembly 150 may be particularly suitable for use with netting coveringmaterials. In addition, the product covering can be held (stretchedaxially) to be relatively tight and substantially centered about theencased product. The tightness or tension of the covering material maybe adjusted by varying the force that the gripper members 151, 152 applyto the chute 30. Where a pneumatic cylinder 153 is used, theforce/tension adjustment can be carried out by adjusting the airpressure delivered to the cylinder 153. A pressure regulator for thisoperation may be disposed on the HMI 55 (FIG. 8).

As also shown in FIGS. 24-26, a covering material (i.e., netting)support roller 157 may be positioned adjacent a bottom portion of theproduct chute 30 to help guide/direct the covering material off thechute 30. Other guides may also be used such as rings that reside overthe outside of the material on the chute 30 and/or the inside of thechute 30 under the material (not shown).

FIG. 29 illustrates a netting covering material 100 c positioned overthe chute 30 with a gathering plate 142 positioned proximate to anddownstream of the product chute 30. FIG. 30 illustrates gathering plates141, 142 and the actuation cylinder 147. FIG. 30 also illustrates thatthe covering material 100 c proximate the discharge end of the chute 30has a closed end portion 100 e ready to receive the next product as itexits the chute 30 to thereby pull the netting material about itself asthe product moves forward to enclose the product therein.

FIGS. 31-35 illustrate an exemplary clipper 40 according to embodimentsof the present invention. The clipper 40 may be particularly suitablefor clipping netting but may be used for other materials as well. As,shown, gathering plates 143 and 144 are mounted to the lower portion ofthe clipper 40 with the clip window 40 w therebetween. The clipper 40includes a pivot attachment aperture 40 p that is sized and configuredto receive a shaft therethrough, which can be supported by the apparatus10 (such as by two trunnion type arms as shown in FIG. 1) to pivotallymount the clipper to the apparatus frame. The clipper 40 can alsoinclude a rotary actuator cam and yoke assembly 40A that, in operation,cooperate to move the clipper 40 in and out of operative position aboutthe travel path of the product. The rotary actuator cam and yokeassembly 40A may include an actuator 41, a cam 42 and yoke 43. Theclipper body can be attached to the actuator 41 via an eccentricallyconfigured cam and yoke 42, 43. The actuator 41 can be a 180-degreepneumatic actuator. The distance from the center of the cam and rotaryactuator centerline can be about one-half that of the distancecorresponding to the movement distance of the clipper 40 from homeposition to the operative clipping position. Fine adjustment travel canbe carried out using an adjustable linkage with left and right handthreads. A manual rotation knob 41 b can also be used to move theclipper 40 back and forth. As shown in FIG. 31, a position flag 41 f canbe provided on a coupler for a proximity sensor(s) mounted to the rotaryactuator assembly 40A.

FIGS. 31-35 and 36-41 also illustrate the clipper 40 with a modularinterchangeable first cutting cartridge 160 ₁. FIGS. 42-45 illustrate asecond modular cutting cartridge 160 ₂. Each cartridge 160 ₁, 160 ₂ hasa respective retractable cutting implement 160 k ₁, 160 k ₂ and anassociated actuator 160 a. In operation, after a clip(s) is applied tothe gathered covering material 100C, the cutting implement 160 k ₁, 160k ₂ can be automatically extended to sever the material. The firstcartridge 160 ₁ is configured to cut through the gathered coveringmaterial. The second cartridge 160 ₂ is configured to apply a differenttype of cutting technique than that of the first cartridge 160 ₁. Forexample, the second cartridge 160 ₂ can be configured to apply heat toslice through the gathered covering material using a “hot-knife”. Othertypes of cutting or severing techniques may also be used such as laser,pressurized fluid (water, air and the like) or other suitable means.

Each cartridge 160 ₁, 160 ₂ includes a platform 160 p that is configuredto slidably insert in a receiving channel or groove 160 g on the clipper40. The desired modular cutting cartridge 160 ₁, 160 ₂ can be selectedand using a quick disconnect feature, interchanged and used asappropriate for the type of covering material in the apparatus 10.

FIG. 37 illustrates that the first cartridge 160 ₁ may include astabilizer block 160 b attached to the forward portion of the rodintermediate the actuator 160 a and the knife 160 k ₁ to help keep theknife 160 k ₁ from rotating upon retraction or extension. FIG. 40illustrates the first cartridge 160 ₁ cutting implement 160 k ₁ (i.e.,knife) in the extended or actuated position.

FIGS. 42-45 illustrate the second cutting cartridge 160 ₂ having ahot-knife configuration. Examples of suitable hot-knife devices aredescribed in U.S. Pat. Nos. 4,683,700 and 5,161,347, the contents ofwhich are hereby incorporated by reference as if recited in full herein.As shown in FIG. 42, the second cartridge 160 ₂ includes a platform 160p, a heat source 160 h (such as a cartridge heater) and a cutting anvil160 k ₂. The cutting anvil 160 k ₂ is heated by the heat source 160 hand, in operation, automatically extended and retracted using the PLCand/or apparatus controller. FIG. 45 illustrates the heat source mountedto the cartridge 160 ₂ without the anvil 160 k ₂ for clarity ofoperation. As for the first cartridge 160 ₁, the second cartridge 160 ₂may include a stabilizer (anti-rotation) block 160 b attached to theactuator rod 160 r intermediate the anvil 160 k ₂ and the actuator 160a. In operation, upon actuation, the cylinder 160 a extends the cuttinganvil 160 k ₂ until the anvil contacts the covering material (i.e.,netting). The material severs as a result of contact with the heatedanvil 160 k ₂. In certain embodiments using covering materials havingcertain types of fibers, the covering material fibers may melt andthermodynamically seal any loose ends thereby capturing particles thatmay otherwise become loose.

FIG. 44 illustrates that the platform 160 p may include an open segment160 s that allows the cartridge heater 160 h to advance with the cuttinganvil 160 k ₂. In other embodiments, the heat source 160 h may be staticand/or the anvil 160 k ₂ advance and retract independently thereof (notshown).

FIGS. 36-41 also illustrate that the clipper 40 may include a gatemember 165 that has an open (FIGS. 36, 37) and closed (FIGS. 38-40)configuration. The gate member 165 can be pivotally attached to theclipper. As shown in FIG. 41, the gate member 165 can include a reliefslot 165 s for the knife 160 k ₁ (or 160 k ₂) to pass through during thesevering operation. FIG. 36 illustrates that the clipper 40 can includea clip-forming die 180 held by a die support 180 s (shown with the leftgathering plate removed to illustrate the spatial relationship of thegathering plate and die according to certain embodiments of theinvention). In operation, as shown in FIG. 36, the covering material100C is gathered against the die support 180 s with the gate 165 openand the cutting implement 160 k ₁ (or 160 k ₂) retracted. The product tobe clipped is typically held off the die 180 to inhibit the legs of theclip from puncturing the product as the legs of the clip warp around theend portion of the covering material encasing the product.

FIG. 37 is shown with the left die removed (in a dual clipperembodiment) to illustrate the spatial relationship of the die 180 andthe cutting implement 160 k ₁ (or 160 k ₂). In operation, the gatemember 165 can automatically deploy via actuator 146 to close and helpgather the covering material prior to firing of the punch and/or clipapplication and can form the outboard side of a clipping channel (40 ch,FIG. 40). FIG. 38 illustrates the gate member 165 closed and pushing thegathered material tightly against the die support 180 s above the die180. FIG. 39 illustrates the gate 165 rotated down and closed and a clippunch 191 partially fired positioned above a clip 190 during theclipping process. The gate member 165, shown translucent, can form theoutboard side of the clip channel as noted above. Once the punch 191reaches the end of its stroke, the ends of the clip(s) 190 is wrappedtogether upon contact with the die 180 gathering the material eventighter together. The cutting cartridge 160 ₁ (or 160 ₂) willautomatically extend the cutting implement 160 k ₁ (or 160 k ₂) once thepunch cylinder reaches the end of its stroke. In the cutting operationshown, the knife 160 k ₁ will slice through the covering material 100Cas it advances, as shown, for example in FIG. 40.

Generally stated, referring to FIG. 31, the clipper 40 defines aclosure/clip delivery path using clip rail 40 c in communication withthe clip window 40 w in a clip channel 40 ch for receipt of a U-shapedmetal clip. The clip is advanced in the closure path or channel by meansof a punch so that the clip will engage a die 180 (FIG. 39) positionedin a manner permitting the clip to be formed about gathered materialthat encases the product in the material at a closure zone in theproduct travel path. Although not illustrated, pressurized air or othermeans of pressing or moving the clip to close about the tubular packagemay also be used. As shown, the guide rail 40 c can have a curvilinearconfiguration with a vertical run which is curved at its lower end sothat it gradually merges into a horizontal run to direct clips mountedthereon into the window 40 w. The clips are typically arranged in astack with adjacent clips abutting each other so that the legs of eachclip fit around the guide rail with a crown of each clip fitting overthe guide rail. The multiple clips may be connected to one another bymeans of a thin elastomeric film, tape or adhesive (typically along thecrown) so that the clips together may slide down the guide rail andaround the bend therein between the vertical and horizontal runs of theguide rail. Typically, clips are provided in a coil or on a reel forfeeding onto the guide rail. Although illustrated herein as a generallyvertical and downwardly directed clip feed, other feed orientations mayalso be employed.

Summarized, when a product or target object enters the product transferzone 60 (FIG. 1), its presence can be automatically determined and theapparatus controller can then activate an automated cycle. The automatedcycle can include: stopping the infeed conveyor from advancing andactuating the product pusher assembly cylinder 21. The product pusherhead 20 h attached to the product pusher cylinder 21 and guide rods 22,23 advance to engage the target product, which is pushed through theproduct chute 30 encased in covering material (i.e., netting) upon exitfrom the product chute 30. Upon exiting the product chute 30, theencased product is pushed onto the product table 76. When the productpusher assembly 20 reaches the end of its forward stroke, its positionis detected by a sensor such as a Hall-effect switch, and the productholding member 75 is actuated. Then, the product pusher assembly 20 isretracted into the product chute before the covering material isgathered and clipped. The product pusher cylinder 21 does not have to befully retracted prior to initiation of the automated gathering andclipping operations. Once the product pusher head 20 h clears thedischarge end of the product chute 30, an intermediate sensor, such asanother Hall-effect switch, typically placed on the product pushercylinder 21, senses the partial retraction thereof. When the sensor isactivated, the apparatus 10 can automatically (i.e., typically via thePLC) proceed to initiate the gathering and clipping operations.

Thus, substantially concurrently to the retraction of the pusher head 20h, the clipper 40 automatically pivots into position thereby advancingthe clipper gathering plates 143, 144, and the netting gathering plates141, 142 are extended. The gathering plates 141-144 converge to theproduct centerline to converge the covering material into a rope-likeconfiguration. Then two closure clips can be applied thereto. Thedownstream clip ends the first product and the upstream clip defines thefirst end portion of the next product. The cutting cartridge is actuatedand the covering material is severed between the two clips. Once thesevering is complete, the cutting cartridge is retracted and theapparatus 10 can automatically start a reset cycle by opening theclipper gate 165, returning the clipper 40 to its home position, and thenetting gathering plates 141, 142 to their home position. Theproduct-holding member 75 can be moved and the product released totravel downstream. When the clipper 40 and gathering plates 141, 142 aresubstantially in their home position, the apparatus 10 can begin thecycle again. When the product pusher assembly 20 reaches its retractedconfiguration, the infeed conveyor 50 f can be started again so thatwhen the reset is complete, another product is in position for entryinto the product chute 30. In each case if a product is not detected inthe transfer zone 60 in a predetermined time, the apparatus 10 can shutoff and wait for a start signal to reactivate the process/apparatus,such as via a pushbutton at the HMI station.

The operation and sequence of events can be controlled by a programmablelogic controller. Certain operations may be selected by an operatorinput using a Human Machine Interface to communicate with the controlleras is well known to those of skill in the art.

FIG. 47 illustrates exemplary operations that may be carried outaccording to embodiments of the present invention. As shown, at leastone target object can be pushed through a product chute automatically(block 300). The initiation of the automatic pushing operation can bebased on a sensed presence of the target object in a product transferzone. A covering material can be pulled downstream off the exteriorsurface of the product chute (which includes pulling from a coveringmaterial mounting device mounted over the product chute) toautomatically enclose the object in the covering material as the productexits the product chute (block 310). A clip(s) can be applied to thecovering material to secure the object in the covering material (block315). The covering material can be automatically selectively slowed orinhibited from further release by applying a braking force theretopressing the covering material against the outer surface of the productchute (block 311). In addition, a gathering of the covering material maybe automatically carried out after the object exits the chute byadvancing gathering plates toward the object (block 312).

FIG. 48 is a block diagram of exemplary embodiments of data processingsystems that illustrates systems, methods, and computer program productsin accordance with embodiments of the present invention. The dataprocessing systems may be incorporated in a programmable logiccontroller and/or be in communication therewith. The processor 410communicates with the memory 414 via an address/data bus 448. Theprocessor 410 can be any commercially available or custommicroprocessor. The memory 414 is representative of the overallhierarchy of memory devices containing the software and data used toimplement the functionality of the data processing system. The memory414 can include, but is not limited to, the following types of devices:cache, ROM, PROM, EPROM, EEPROM, flash memory, SRAM, and DRAM.

As shown in FIG. 48, the memory 414 may include several categories ofsoftware and data used in the data processing system: the operatingsystem 452; the application programs 454; the input/output (I/O) devicedrivers 458; the Automated Product Pusher and Clipper Actuation Modules450; and the data 456.

The data 456 may include a look-up chart of different products, pushingrates, covering material lengths, proximity sensor feedback, safetyinterlock circuits and the like 451 corresponding to particular ortarget products for one or more producers, which may allow an operatorto select certain operational parameters at the start of each shiftand/or production run and the like.

As will be appreciated by those of skill in the art, the operatingsystem 452 may be any operating system suitable for use with a dataprocessing system, such as OS/2, AIX, DOS, OS/390 or System390 fromInternational Business Machines Corporation, Armonk, N.Y., Windows CE,Windows NT, Windows95, Windows98 or Windows2000 from MicrosoftCorporation, Redmond, Wash., Unix or Linux or FreeBSD, Palm OS fromPalm, Inc., Mac OS from Apple Computer, LabView, or proprietaryoperating systems. The I/O device drivers 458 typically include softwareroutines accessed through the operating system 452 by the applicationprograms 454 to communicate with devices such as I/O data port(s), datastorage 456 and certain memory 414 components. The application programs454 are illustrative of the programs that implement the various featuresof the data processing system and preferably include at least oneapplication, which supports operations according to embodiments of thepresent invention. Finally, the data 456 represents the static anddynamic data used by the application programs 454, the operating system452, the I/O device drivers 458, and other software programs that mayreside in the memory 414.

While the present invention is illustrated, for example, with referenceto the Automated Product Pusher and Clipper Actuation Modules 450 beingan application program in FIG. 48, as will be appreciated by those ofskill in the art, other configurations may also be utilized while stillbenefiting from the teachings of the present invention. For example, theModules 450 may also be incorporated into the operating system 452, theI/O device drivers 458 or other such logical division of the dataprocessing system. Thus, the present invention should not be construedas limited to the configuration of FIG. 48, which is intended toencompass any configuration capable of carrying out the operationsdescribed herein.

The I/O data port can be used to transfer information between the dataprocessing system, the product pusher, and the closure attachmentmechanism or another computer system or a network (e.g., the Internet)or to other devices controlled by the processor. These components may beconventional components such as those used in many conventional dataprocessing systems which may be configured in accordance with thepresent invention to operate as described herein.

For example, certain embodiments of the present invention are directedto a computer program product for operating an automated clipped(netting) packaging apparatus. The automated packaging apparatus caninclude an automated product pusher mechanism that advances and retractsfrom a product chute and an automated clipping apparatus that applies atleast one closure clip to netting thereat. The computer program productcan include: (a) computer readable program code that automaticallycontrollably actuates a pusher actuation cylinder to push a productpusher in a downstream direction; and (b) computer readable program codethat automatically controllably actuates a clipper mechanism to positiona clipping apparatus in a clipping position in response to productpushed by the product pusher out of the product chute and covered innetting.

In particular embodiments, the computer program product can also includeone or more of: (a) computer readable program code that automaticallycontrollably actuates netting gathering plate actuation cylinders tolaterally translate the plates toward the clipper mechanism; (b)computer readable program code that automatically controllably actuatesa package holding member to raise the holding member above a productsupport floor to maintain a product held in netting in alignment withthe clipper mechanism; (c) computer readable program code that monitorsa proximity sensor positioned to detect when a product is in position tobe packaged and then automatically controllably actuates the pushercylinder in response thereto; (d) computer readable program code thatprevents actuation of the pusher cylinder when the product chute is notin proper position; (e) computer readable program code that actuates acutting tool actuation cylinder to controllably advance the cutting tooland automatically sever netting intermediate two clips thereon; (f)computer readable program code that supplies heat to the cutting tool;(g) computer readable program code that automatically actuates clippushers in the clipper mechanism when netting is gathered and inposition for clipping at the clipping window; (h) computer readableprogram code that controls the actuation of a braking mechanism toadvance the braking mechanism to contact the product chute andselectively apply pressure to netting thereat; (i) computer readableprogram code that automatically controllably actuates the pusheractuation cylinder to pull a product pusher in an upstream direction outof the product chute; and (j) computer readable program code thatautomatically controllably actuates the clipper mechanism to remove theclipping apparatus from the clipping position.

While the present invention is illustrated, for example, with referenceto particular divisions of programs, functions and memories, the presentinvention should not be construed as limited to such logical divisions.Thus, the present invention should not be construed as limited to theconfiguration of FIG. 48 but is intended to encompass any configurationcapable of carrying out the operations described herein.

The flowcharts and block diagrams of certain of the figures hereinillustrate the architecture, functionality, and operation of possibleimplementations of selective implementation of single and dual clipclosure means according to the present invention. In this regard, eachblock in the flow charts or block diagrams represents a module, segment,or portion of code, which comprises one or more executable instructionsfor implementing the specified logical function(s). It should also benoted that in some alternative implementations, the functions noted inthe blocks may occur out of the order noted in the figures. For example,two blocks shown in succession may in fact be executed substantiallyconcurrently or the blocks may sometimes be executed in the reverseorder, depending upon the functionality involved.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention as defined inthe claims. In the claims, means-plus-function clauses, where used, areintended to cover the structures described herein as performing therecited function and not only structural equivalents but also equivalentstructures. Therefore, it is to be understood that the foregoing isillustrative of the present invention and is not to be construed aslimited to the specific embodiments disclosed, and that modifications tothe disclosed embodiments, as well as other embodiments, are intended tobe included within the scope of the appended claims. The invention isdefined by the following claims, with equivalents of the claims to beincluded therein.

1. An automated pusher mechanism that cooperates with a clipper, thepusher mechanism having a pusher head, wherein the pusher head comprisesa forward portion adapted to contact a target product attached to a pairof laterally spaced apart longitudinally and rearwardly extendingsidewalls, wherein the sidewalls each have an arcuate outer surface anda planar inner surface and are oriented so that the planar innersurfaces face each other, and wherein, when viewed from above, theforward portion comprises an inverted “V” shape with side portions thatangularly converge in a rearward direction to a valley, and wherein thevalley resides proximate a forward portion of the sidewalls.
 2. Thepusher mechanism of claim 1 in combination with a product chute, thepusher head adapted to contact a product, wherein the pusher headreciprocates in and out of the product chute, and wherein the productchute has an open cavity extending therethrough with open ingress andegress portions, with the clipper residing downstream of the productchute.
 3. The pusher mechanism of claim 2, wherein the pusher mechanismcomprises a single actuation rod that is attached to an actuationcylinder at one end portion and to a laterally medial portion of thepusher head at the other end portion, and first and second guide rods,one each attached to respective sidewalls of the pusher head andextending rearwardly on opposing sides of the actuation rod, wherein theguide rods reciprocate in concert with the actuation rod into and out ofat least an ingress end of the product chute.
 4. The pusher mechanism ofclaim 3, wherein a forward portion of the pusher head exits a dischargeend portion of the product chute at a forwardmost stroke position, whilethe first and second guide rods attached to the pusher head resideinside the product chute.
 5. A packaging system, comprising: a clipper;a product chute residing upstream of the clipper, the product chutehaving an open cavity extending therethrough with opposing open ingressand egress portions; a pusher mechanism having a pusher head, whereinthe pusher head comprises a forward portion adapted to contact a targetproduct attached to a pair of laterally spaced apart outerlongitudinally and rearwardly extending sidewalls, each with an arcuateouter surface and a planar inner surface, oriented so that the planarinner surfaces face each other, wherein, when viewed from above, theforward portion comprises side portions that angularly converge in arearward direction to a valley, and wherein the valley resides proximatea forward portion of the sidewalls.
 6. The system of claim 5, whereinthe pusher mechanism comprises a single actuation rod with first andsecond opposing end portions, the first end portion attached to anactuation cylinder and the second end portion attached to the pusherhead.
 7. The system of claim 6, further comprising laterally spacedapart first and second guide rods attached to opposing sides of thepusher head and extending rearwardly on opposing sides of the actuationrod, wherein the guide rods reciprocate in concert with the actuationrod into and out of at least the ingress end of the product chute. 8.The system of claim 7, wherein a forward portion of the pusher headexits a discharge end portion of the product chute at a forwardmoststroke position, while the first and second guide rods attached to thepusher head reside inside the product chute.
 9. The system of claim 5,wherein the forward portion of the pusher head is releasably attached tothe sidewalls.
 10. The system of claim 5, wherein the sidewalls definean open gap space therebetween, and wherein a forward portion of anelongate actuation member attached to the pusher head resides in theopen gap space.